Frame for receiving a filter element and method for providing

ABSTRACT

Provided is an apparatus for receiving a filter member. The apparatus, in this embodiment, includes a plurality of discrete substantially rigid frame sections. In this embodiment, each respective section of the plurality of sections lies generally in a respective plane substantially oriented about a respective axis and has a respective length greater than a respective width. Furthermore, in this embodiment, the plurality of sections are joined width-to-width generally oriented with respect to a plane in an assembled orientation to circumscribe a quadrilaterally bound zone for effecting said receiving. Further to this embodiment, adjacent portions of respective joined sections in the assembled orientation establish respective joining structures. Even further to this embodiment, each respective joining structure maintains the adjacent portions oriented substantially about a respective axis.

CROSS REFERENCE RELATED APPLICATION

This Application is a Divisional of U.S. application Ser. No. 11/954,207filed on Dec. 11, 2007, to Ammar Kailani, et al., entitled “FRAME FORRECEIVING A FILTER ELEMENT AND METHOD FOR PROVIDING,” currently allowed;commonly assigned with the present invention and incorporated herein byreference.

BACKGROUND OF THE INVENTION

The present invention is directed to frames for receiving filterelements, and especially to frames for receiving air filter elements foruse in heating, ventilating and air conditioning (HVAC) systems.

HVAC systems may include or employ filter elements for removingparticles or other elements from air circulated within the system inorder to provide cleaner air for spaces serviced by the system. The airfilter elements may be supported in predetermined positions within anair duct or similar locus in the HVAC system. The filter elements mayrequire removal for replacement or cleaning. It is preferred thatreplacement filters with associated frames for supporting the elementsin a duct or other locus in an HVAC system may occupy little storagespace and present a compact package for shipping to storing sites or tousers.

There is a need for a frame for supporting a filter element that may beconfigured to be collapsible yet may provide substantially strongsupport for a filter element in when in an assembled orientation andemployed for receiving a filter element.

SUMMARY OF THE INVENTION

Provided is an apparatus for receiving a filter member. The apparatus,in this embodiment, includes a plurality of discrete substantially rigidframe sections. In this embodiment, each respective section of theplurality of sections lies generally in a respective plane substantiallyoriented about a respective axis and has a respective length greaterthan a respective width. Furthermore, in this embodiment, the pluralityof sections are joined width-to-width generally oriented with respect toa plane in an assembled orientation to circumscribe a quadrilaterallybound zone for effecting said receiving. Further to this embodiment,adjacent portions of respective joined sections in the assembledorientation establish respective joining structures. Even further tothis embodiment, each respective joining structure maintains theadjacent portions oriented substantially about a respective axis.

Provided, in another embodiment, is a method for providing a frame forreceiving a filter element. The method, in this embodiment, includesproviding a pair of first members, and providing a pair of secondmembers. Further to this embodiment, the method includes arranging thefirst members alternately with the second members in an assembledorientation to establish a plurality of joining structures betweenadjoining first and second members, wherein each respective joiningstructure maintains the members oriented substantially about arespective axis, and further wherein the first members and the secondmembers cooperate to define a volume for effecting said receiving.

Further features of the present invention will be apparent from thefollowing specification and claims when considered in connection withthe accompanying drawings, in which like elements are labeled using likereference numerals in the various figures, illustrating the preferredembodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an assembled frame apparatus with areceived filter element.

FIG. 2 is a top plan view of a first member of the frame illustrated inFIG. 1.

FIG. 3 is a bottom plan view of the first member illustrated in FIG. 2.

FIG. 4 illustrates details of the first member, viewed along sectionline 4-4 in FIG.

FIG. 5 is a perspective view of the first member being assembled with afilter element.

FIG. 6 is an end view of the first member, viewed along section line 6-6in FIG. 1.

FIG. 7 is a top plan view of a second member of the frame illustrated inFIG. 1.

FIG. 8 is a side view of the second member, viewed along section line8-8 in FIG.

FIG. 9 is a bottom plan view of the second member illustrated in FIG. 7.

FIG. 10 is an end view of the second member illustrated in FIGS. 7-9,viewed along section line 10-10 in FIG. 9.

FIG. 11 is a section view of a latching insertion structure, viewedalong section line 11-11 in FIG. 9.

FIG. 12 is a section view of an insertion structure, viewed alongsection line 12-12 in FIG. 9.

FIG. 13 is a schematic side view of a ramp structure poised forengagement with a stop portion.

FIG. 14 is a schematic side view of a ramp structure in the process ofengaging with a stop portion.

FIG. 15 is a schematic side view of a ramp structure engaged with a stopportion.

FIG. 16 is a flow chart illustrating an embodiment of the method of theinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 is a perspective view of an assembled frame apparatus with areceived filter element. In FIG. 1, a frame apparatus 10 includes a pairof first members 12, 14 arranged alternately with a pair of secondmembers 16, 18 to establish a plurality of joining structures 20, 22,24, 26. Joining structure 26 is not clearly visible in FIG. 1.Preferably, joining structure 26 is substantially similar to joiningstructures 20, 22, 24. Joining structure maintains adjoining members 12,16 oriented substantially about a linear axis 30. Joining structure 22maintains adjoining members 12, 18 oriented substantially about a linearaxis 32. Joining structure 24 maintains adjoining members 14, 18oriented substantially about a linear axis 34. Joining structure 26maintains adjoining members 14, 16 oriented substantially about a linearaxis 36.

In the assembled orientation illustrated in FIG. 1, members 12, 14, 16,18 cooperated through joining structures 20, 22, 24, 26 to define avolume 40 for receiving a filter element 42.

FIG. 2 is a top plan view of a first member of the frame illustrated inFIG. 1. FIG. 3 is a bottom plan view of the first member illustrated inFIG. 2. Regarding FIGS. 2 and 3 together, first frame member 12 includesa substantially planar base portion 50 supporting spaced tab members 52,54. First frame member 12 has a length L.sub.1 and a width W.sub.1.Length L.sub.1 is greater than width W.sub.1.

Spaced tab members 52, 54 present a space between themselves and baseportion 50 (not specifically illustrated) to permit a slidinginstallation of a planar base member for filter element 42 to removableaffix filter element 42 with respect to first member 12 generallyagainst base portion 50. This installation of filter member 42 withfirst member 12 is illustrated in greater detail in FIG. 5.

First member 12 also includes receiver structures 56. Preferably onereceiver structure 56 is situated at each corner of first member 12.Receiver structures 56 are joining elements that may participate inestablishing joining structures 20, 22, 24, 26, as will be described ingreater detail below.

First member 12 also includes stop structures 58. Preferably one stopstructure 58 is situated at each end of first member 12 on the top sideof base portion 50 (visible in FIG. 2). Stop structures 58 are joiningelements that may also participate in establishing joining structures20, 22, 24, 26, as will be described in greater detail below.

First frame member 14 may be substantially similar to first frame member12. In order to avoid prolixity, a repetitive description of first framemember 14 will not be presented.

FIG. 4 illustrates details of the first member, viewed along sectionline 4-4 in FIG. 1. In FIG. 4, a receiver structure 56 includes an upperwall 60, a lower wall 62, a rear wall 66 and a front wall 66 (notvisible in FIG. 4, see FIG. 2). Walls 60, 62, 64, 66 define a channel68. Channel 68 is oriented substantially symmetrically about an axis 69.

FIG. 5 is a perspective view of the first member being assembled with afilter element. In FIG. 5, filter element 42 is illustrated in theprocess of sliding engagement with first member 12. Filter element 42includes an air-permeable portion 48 coupled with substantiallyinflexible end portions 44, 46. End portion 44 has a thicknessappropriate for sliding between base portion 50 and spaced tab members52, 54 (see FIG. 2) to establish a slidably removable joining betweenfirst member 12 and end portion 44. End portion 46 is similarlyproportioned to permit similar sliding removable joining with anotherend portion 12 (not shown in FIG. 5). Air-permeable portion 48 may becompressible along an axis 47 substantially perpendicular with endportions 44, 46 to permit orienting filter element 42 in a smallervolume. Such a smaller volume is amenable to shipping filter element 42in a reduced volume package.

FIG. 6 is an end view of the first member, viewed along section line 6-6in FIG. 1. In FIG. 6, a first member in end view presents two receiverstructures 56 on either corner of first member 12, and a stop structure58 generally midway between receiver structures 56. Each receiverstructure 56 includes an upper wall 60, a lower wall 62, a rear wall 64and a front wall 66 establishing a channel 68. Stop structure 58includes a top wall 70 supported in spaced relation from base portion 50of first member 12 by side walls 72, 74. A channel 76 is established bybase portion 50 in cooperation with side walls 72, 74 and top wall 70.Channel 76 may be trapezoidal, as illustrated in FIG. 6. Alternatively,channel 76 may have another quadrilateral shape, a trilateral shape oranother polygonal shape appropriate for receiving an inserted member.

FIG. 7 is a top plan view of a second member of the frame illustrated inFIG. 1. FIG. 8 is a side view of the second member, viewed along sectionline 8-8 in FIG. 7. FIG. 9 is a bottom plan view of the second memberillustrated in FIG. 7. Regarding FIGS. 7-9 together, second frame member16 includes a substantially planar base portion 80. Second frame member16 has a length L.sub.2 and a width W.sub.2. Length L.sub.2 is greaterthan width W.sub.2.

Second member 16 also includes insertion structures 82. Preferably, oneinsertion structure 82 is situated at each corner of second member 16.Second member further includes latching insertion structures 84.Preferably, one latching insertion structure 84 is situated at each endof second member 16 between respective insertion structures 82.

Insertion structures 82 are joining elements that may participate inestablishing joining structures 20, 22, 24, 26 in cooperation withreceiver structures 56 (FIGS. 2, and 6). Each respective insertionstructure 82 at a corner of a second member 16, 18 may be insertedwithin a respective receiver structure 56 at a corner of a first member12, 14 to participate in establishing a respective joining structure 20,22, 24, 26.

Latching insertion structures 84 are also joining elements that mayparticipate in establishing joining structures 20, 22, 24, 26 incooperation with stop structures 58. Each respective latching insertionstructure 84 at an end of a second member 16, 18 may be latchinglyinserted within a respective channel 76 of a stop structure at an end ofa first member 12, 14 to participate in establishing a respectivejoining structure 20, 22, 24, 26. Latching insertion will be describedin greater detail in connection with FIGS. 13-15.

Second frame member 18 may be substantially similar to second framemember 16. In order to avoid prolixity, a repetitive description ofsecond frame member 18 will not be presented.

One skilled in the art of collapsible filter frame manufacture mayrecognize that receiver structures 56, stop structures 58, insertionstructures 82 and latching insertion structures 84 may be placed on anyof first members 12, 14 and second members 16, 18 so long as eachrespective joining structure 20, 22, 24,26 has at least one insertionjoining arrangement and a latching joining arrangement. Each insertionjoining arrangement includes a mating pair of a receiver structure 56with an insertion structure 82. Each latching joining arrangementincludes a mating pair of a stop structure 58 with a latching insertionmember 84. It is preferred that each joining structure include twoinsertion joining arrangements and a latching joining arrangement.

FIG. 10 is an end view of the second member illustrated in FIGS. 7-9,viewed along section line 10-10 in FIG. 9. In FIG. 10, a second member16 presents insertion structures 82 extending from base portion 80 atcorners of second member 16, and presents a latching insertion structure84 from base portion 80 between insertion structures 82. Each insertionstructure 82 presents crossed beams 90, 92 arranged generallyperpendicular to each other to result in a “+” cross-section (viewedfrom the left side of FIG. 10) for insertion within a receiver structure56 (FIGS. 2, 4 and 6) to participate in establishing an insertionjoining arrangement for inclusion in a joining structure 20, 22, 24, 26(FIG. 1). Insertion structure 82 may present any cross-section, such asthe “+” cross-section illustrated In FIG. 10, for insertion withinreceiver structure 56 so long as the fit between insertion structure 82and receiver structure 56 is snug enough to provide a sturdy and solidinsertion joining arrangement for inclusion in a joining structure 20,22, 24, 26. It is desirable that the fit between insertion structure 82and receiver structure 56 be amenable to separation by a user tugginginsertion structure 82 and receiver structure 56 apart. Othercross-sections may be usable for insertion structure 82 such as, by wayof example and not by way of limitation, a quadrilateral cross section,a triangular cross section, a hexagonal cross-section or anothercross-section.

FIG. 11 is a section view of a latching insertion structure, viewedalong section line 11-11 in FIG. 9. In FIG. 1, a latching insertionstructure 84 depends from base portion 80. Latching insertion structure84 includes a lever portion 100 attached with base portion 80 and alatching portion 102 attached with lever portion 100 distal from baseportion 80. Latching portion 102 includes a flat section 104 generallyconfigured in register with a contiguous portion of lever portion 100, aramp section 106 departs from flat section 104 at an acute angle towardthe general direction of base portion 80. A blocking section 108 extendssubstantially perpendicularly from lever portion 100 to ramp section 106at a locus displaced from the intersection of flat section 104 and rampsection 106. When at rest, lever portion 100 and latching portion 102are oriented generally symmetrically about an initial axis 103.

FIG. 12 is a section view of an insertion structure, viewed alongsection line 12-12 in FIG. 12, an insertion structure 82 depends frombase portion 80. Insertion structure 82 includes crossed beams 90, 92arranged generally perpendicular to each other to result in a “+”cross-section (as viewed from the bottom of FIG. 12) for insertionwithin a receiver structure 56 (FIGS. 2, 4 and 6) to participate inestablishing an insertion joining arrangement for inclusion in a joiningstructure 20, 22, 24, 26 (FIG. 1). Insertion structure 82 may presentany structure for insertion within receiver structure 56 so long as thefit between insertion structure 82 and receiver structure 56 is snugenough to provide a sturdy and solid joining structure 20, 22, 24,26. Itis desirable that the fit between insertion structure 82 and receiverstructure 56 be amenable to separation by a user tugging insertionstructure 82 and receiver structure 56 apart. Other cross-sections maybe usable for insertion structure 82 such as, by way of example and notby way of limitation, a quadrilateral cross section, a triangular crosssection, a hexagonal cross-section or another cross-section.

FIG. 13 is a schematic side view of a ramp structure poised forengagement with a stop portion. FIG. 14 is a schematic side view of aramp structure in the process of engaging with a stop portion. FIG. 15is a schematic side view of a ramp structure engaged with a stopportion. Regarding FIGS. 13-15 together, before a latching engagementoperation is begun lever portion 100 and integrally formed latchingportion 102 are at rest substantially symmetrically oriented about aninitial axis 103. A latching engagement operation is initiated by movingone or both of latching portion 102 and stop structure 58 to displacelatching portion 102 relative to stop structure 58 along an installationpath, indicated by an arrow 105.

As latching portion 102 and stop structure 58 are urged together, rampsection 106 passes within channel 76 between side walls 72, 74 (onlyside wall 72 is shown in FIGS. 13-15) and ramp section 106 bears againsttop wall 70. As latching portion 102 and stop structure 58 are urgedfurther together ramp section 106 is deflected from initial axis 103 andpasses through channel 76. Deflection of ramp section 106 establishes adeflection force in lever portion 100 urging lever portion 100 in thedirection indicated by arrow 107 (FIG. 14).

When the intersection between blocking section 108 and ramp section 106passes clear of top wall 70, ramp section 106 responds to the deflectionforce established in lever portion 100 to return toward symmetry withaxis 103 to a position in which blocking section 108 is in asubstantially abutting relation with top wall 70. Blocking section 108resists removal of latching portion 102 back along the installation path(indicated by arrow 105) without first deflecting latching portion 102from axis 103.

Joining structures 20, 22, 24, 26 (FIG. 1) may thus be established,preferably in combination, by insertion of insertion structures 82within receiver structures 56 and by insertion of latching insertionstructures 84 within stop structures 58. It is preferred that receiverstructures 56, stop structures 58, insertion structures 82 and latchinginsertion structures 84 each be integrally formed with a respectivefirst member 12, 14 or a respective second member 16, 18 as appropriateto establish joint structures 20, 22, 24, 26 substantially rigidly aboutrespective axes 30, 32, 34, 36 (FIG. 1). While any polygonal structuremay be established circumscribing volume 40 (FIG. 1) using the teachingsof the present invention, a preferred polygonal shape is a quadrilateralshape, and especially a rectangular shape. Maintaining a predeterminedpolygonal shape for a filter element contributes to reduced air leakagearound the filter element when it installed in an air duct or otherinstallation site.

FIG. 16 is a flow chart illustrating an embodiment of the method of theinvention. In FIG. 16, a method 200 for providing a frame for receivinga filter element begins at a START locus 202. Method 200 continues by inno particular order: (1) providing a pair of first members, as indicatedby a block 204; and (2) providing a pair of second members, as indicatedby a block 206.

Method 200 continues with the step of arranging the first membersalternately with the second members in an assembled orientation toestablish a plurality of joining structures between adjoining themembers, as indicated by a block 208. Each respective joining structureof the plurality of joining structures maintains the adjoining membersoriented substantially about a respective axis. The first members andthe second members cooperate to define a volume for effecting thereceiving of the filter element.

It is to be understood that, while the detailed drawings and specificexamples given describe preferred embodiments of the invention, they arefor the purpose of illustration only, that the apparatus and method ofthe invention are not limited to the precise details and conditionsdisclosed and that various changes may be made therein without departingfrom the spirit of the invention which is defined by the followingclaims:

1. An apparatus for receiving a filter member, the apparatus comprising:a plurality of discrete substantially rigid frame sections, wherein:each respective section of said plurality of sections lying generally ina respective plane substantially oriented about a respective axis and ahaving a respective length greater than a respective width; saidplurality of sections being joined width-to-width generally orientedwith respect to a plane in an assembled orientation to circumscribe aquadrilaterally bound zone for effecting said receiving; adjacentportions of respective joined sections in said assembled orientationestablishing respective joining structures; and each respective saidjoining structure maintaining said adjacent portions orientedsubstantially about a respective axis.
 2. An apparatus for receiving afilter member as recited in claim 1 wherein each said respective joiningstructure includes at least one joining element; each joining element ofsaid at least one joining element including at least two portions foreffecting a latching relationship between said respective adjoiningmembers.
 3. An apparatus for receiving a filter member as recited inclaim 2 wherein a first portion of said at least two portions isintegrally formed in one of said adjacent sections, and wherein a secondportion of said at least two portions is integrally formed in an otherof said adjacent sections than said one adjacent section.
 4. Anapparatus for receiving a filter member as recited in claim 2 wherein atleast one of said at least one first portion presents a ramp structuregenerally oriented about an initial axis, and wherein at least one saidat least one second portion presents a stop portion; said ramp structurebeing deflected from said initial axis as said ramp structure is urgedagainst said stop portion along an installation path; said rampstructure returning substantially to said initial orientation about saidinitial axis when said ramp structure is urged past said stop portionalong said installation path to an installed orientation; said rampstructure bearing against said stop portion to effect resisting removalback along said installation path when said ramp structure is in saidinstalled orientation.
 5. An apparatus for receiving a filter member asrecited in claim 2 wherein said at least one joining element is at leasttwo joining elements.
 6. An apparatus for receiving a filter member asrecited in claim 3 wherein at least one of said at least one firstportion presents a ramp structure generally oriented about an initialaxis, and wherein at least one said at least one second portion presentsa stop portion; said ramp structure being deflected from said initialaxis as said ramp structure is urged against said stop portion along aninstallation path; said ramp structure returning substantially to saidinitial orientation about said initial axis when said ramp structure isurged past said stop portion along said installation path to aninstalled orientation; said ramp structure bearing against said stopportion to effect resisting removal back along said installation pathwhen said ramp structure is in said installed orientation.
 7. Anapparatus for receiving a filter member as recited in claim 6 whereinsaid at least one joining element is at least one latching structure andtwo guiding structures; each guiding structure of said at least twoguiding structures including a guide member in said one adjacent sectionslidingly received within a receiving structure in said other adjacentsection.
 8. A method for providing a frame for receiving a filterelement; the method comprising: providing a pair of first members;providing a pair of second members; and arranging said first membersalternately with said second members in an assembled orientation toestablish a plurality of joining structures between adjoining first andsecond members, wherein each respective joining structure maintains saidmembers oriented substantially about a respective axis, and furtherwherein said first members and said second members cooperate to define avolume for effecting said receiving.
 9. A method for providing a framefor receiving a filter element as recited in claim 8 wherein each saidrespective joining structure includes at least one joining element; eachjoining element of said at least one joining element including at leasttwo portions for effecting a latching relationship between saidrespective adjoining members.
 10. A method for providing a frame forreceiving a filter element as recited in claim 9 wherein a first portionof said at least two portions is integrally formed in one of saidadjoining structures, and wherein a second portion of said at least twoportions is integrally formed in an other of said adjoining structuresthan said one adjoining structure.
 11. A method for providing a framefor receiving a filter element as recited in claim 9 wherein at leastone of said at least one first portion presents a ramp structuregenerally oriented about an initial axis, and wherein at least one saidat least one second portion presents a stop portion; said ramp structurebeing deflected from said initial axis as said ramp structure is urgedagainst said stop portion along an installation path; said rampstructure returning substantially to said initial orientation about saidinitial axis when said ramp structure is urged past said stop portionalong said installation path to an installed orientation; said rampstructure bearing against said stop portion to effect resisting removalback along said installation path when said ramp structure is in saidinstalled orientation.
 12. A method for providing a frame for receivinga filter element as recited in claim 9 wherein said at least one joiningelement is at least two joining elements.
 13. A method for providing aframe for receiving a filter element as recited in claim 9 wherein atleast one of said at least one first portion presents a ramp structuregenerally oriented about an initial axis, and wherein at least one saidat least one second portion presents a stop portion; said ramp structurebeing deflected from said initial axis as said ramp structure is urgedagainst said stop portion along an installation path; said rampstructure returning substantially to said initial orientation about saidinitial axis when said ramp structure is urged past said stop portionalong said installation path to an installed orientation; said rampstructure bearing against said stop portion to effect resisting removalback along said installation path when said ramp structure is in saidinstalled orientation.